BUILD THREAD For 1964 Falcon Sprint to Monte Carlo Rallye FIA spec'

[Paul B]

I saw this last Sunday at the Oilers Hot Rod Club's brekkie meet here in Tauranga - A bit different to yours.

[ATTACH=CONFIG]65150[/ATTACH]

Thanks Nigel, That the Aussie version of my Falcon, they share; roof, glass, floor pan, sills & seats (A few other bit & pieces) and that's about it. This Falcon was the first year of the Aussie break away design model (from USA design) Getting hard to find nice Aussie falcon coupes now. Cheers

[Paul B]

Here is a neat clip of a Falcon Rally Sprint in Germany on a hill climb[video=facebook_share;1463243463741962]https://www.facebook.com/104918969574425/videos/1463243463741962/[/video]

[Paul B]

The wiring is all finished off now and circuit tested, all systems are go and fully functioning.

Now it is on to suspension and brakes

[Oldfart]

I have definitely run out of superlatives to be able to comment Paul.

[Roger Dowding]

I have definitely run out of superlatives to be able to comment Paul.

Rhys you are not alone, brilliant car.. Thanks Paul B ..

[Paul B]

Thanks guys!
It will be good when it can turn its wheels under its own steam.... preferably rather quickly

[Paul B]

The rest of my parts arrived yesterday from USA, so I could get on with the front suspension. I fitted the upper and lower control arms, new springs, restored the torsion bar, and fitted the HD spindles.
The 1964 V8 Falcons had from factory, heavy duty tierod ends, and matching spindles, the drag link and idler arm housing was also HD (you can see it has 3 bolt idler arm housing on the chassis vs Mustang 2 bolt) . When Holman Moody built the 15 cars they replaced the OEM spindle with another heavy duty larger spindle and also used their own HD spring perch as shown.

[Bruce302]

Nice

[Paul B]

Thanks Bruce,
I have been fitting the original type Kelsey Hayes 4 pot calipers and rotors, Right side, I needed to rework the rotor back plates to fit the HD spindles. These are the same brakes that were used on the later Mustang GT350s but the Falcon Rallye Sprints also had an in line Hydrovac booster mounted where the battery was.

This is a picture of the 1964 FIA Homologation 1250 Left Front brakes

Very interesting, I found an article on Kelsey Hayes brakes and the Chrysler Valiant entered in the 1964 Monte Carlo Rallye also had the very same brakes as the Falcon.

[Andrew Metford]

Not trying to be a rivet-counter, but are grooved rotors period correct??

[Paul B]

No they are not, but they are only decent rotors found so far, most of the non grooved ones are not produced from very good quality material. Still looking, these will do for the meantime till I find something else.

[Andrew Metford]

Didn't know that. Wow. You don't want second rate materials in the brakes, so I can well and truly understand your decision there!!!

[Paul B]

Rotor warping is a real pain especially under track conditions , bedding them and heat prepping helps a lot but if the metallurgy is not up to scratch it can be more rotor change outs and reskimming etc. Cheers

[Paul B]

I made up all of the front brake lines for the master cylinder to booster, booster to junction and to front wheels, then fitted them up. I also finished fitting the brakes and torqued everything down. A lot of brake lines with a remote in line booster but that's how they were made.

And spaghetti junction,

[Paul B]

Fitted the anti sway bar and some other parts and torqued the front brake and suspension components down, re checked the camber and caster. That completes the front suspension and brakes assembly.
On to the steering now to finish that off.

[Andrew Metford]

Beautiful work!!

[Paul B]

Thanks Andrew, Getting there... slowly
I fitted some interior and the front screen with the wipers too, and they work!

Also had to buff & polish the 55 year old Stainless trim, started with this

Here is the finished job

Screen & Wipers fitted also

[Paul B]

A few more jobs done
Fitted the front upper outer shock tower supports I fabricated earlier

Also gave the Borg Warner T10 a birthday, this is the first of the Super T10s with 28 spline output.

It is always interesting seeing the different ways people have reassembled parts over the years in places they should not be.
Also this is a picture of all the RTV I found in places it should not be.

[Paul B]

I have completed the body and trim assembly and the interior also. The wiring is all done and the alternator conversion with diode install is all completed. ready for engine, gearbox and driveline now.

So this is the road going version to get it road registered and then it will come back for the roll cage etc, it will be running complete interior as the cars did in 1964.

[khyndart in CA]

Paul,
Your workmanship and attention to detail is absolutely outstanding.
Even the garage floor is spotless. Well done mate.
Although your dear wife must get a lot of credit as she waited patiently for you as you spent time with your second love !

Hey, perhaps one day we can link up and spend some time together..

(Alamy photo )

Cheers,
Ken H